JP2015162500A - Semiconductor device manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a semiconductor device manufacturing method which can remove a salient of a compound semiconductor layer while suppressing exposure of an active layer and an etching amount of an upper semiconductor layer without involving a damage.SOLUTION: A semiconductor device manufacturing method comprises: a laser part formation process of forming on a part of a substrate, a laser part provided with an active layer, an upper semiconductor layer formed on the active layer and a mask formed on the upper semiconductor layer; a semiconductor layer formation process of forming a compound semiconductor layer by an In-containing material, which contacts lateral faces of the laser part and has salients at parts contacting the laser part; and a wet etching process of removing the salients by an etchant containing hydrobromic acid and acetic acid to planarize the compound semiconductor layer. By the wet etching process, (111)A surfaces are formed on the upper semiconductor layer under the mask.

Description

  The present invention relates to a method for manufacturing a semiconductor device used for optical communication, for example.

  Patent Document 1 discloses that when a compound semiconductor layer (InP buried layer) is epitaxially grown on the left and right sides of a ridge stripe, convex portions are formed in the compound semiconductor layer. The technique disclosed in Patent Document 1 wet-etches the convex portion using an etchant made of hydrochloric acid, acetic acid, and hydrogen peroxide.

JP 2002-246684 A

  The convex portions of the compound semiconductor layer are desirably removed because they deteriorate the characteristics of the semiconductor device. This convex portion can be removed by wet etching. However, there is a problem that the upper semiconductor layer that is in contact with the compound semiconductor layer and formed on the active layer is etched by the wet etching to expose the active layer. When the active layer is exposed, the surface of the active layer is oxidized and the optical confinement property of the semiconductor device is deteriorated. Therefore, the active layer should not be exposed when removing the protrusions. Further, since the light confinement effect is impaired when the etching amount of the upper semiconductor layer is increased, the etching amount of the upper semiconductor layer should be suppressed.

  In the technique disclosed in Patent Document 1, etching of the clad layer is prevented by a contact layer and a speed adjustment layer on the clad layer (upper semiconductor layer) when the convex portion is wet-etched. In order to reliably prevent the cladding layer from being etched, it is necessary to increase the thickness of the contact layer and the speed adjusting layer, which increases the manufacturing cost. Further, the dopant doped in the contact layer diffuses due to the high temperature at the time of forming the compound semiconductor layer, thereby deteriorating the characteristics of the semiconductor device.

  In Patent Document 1, in order to suppress the etching of the cladding layer, the growth stop surface (111) surface constituting the convex portion of the compound semiconductor layer is made higher than the upper surface of the speed adjustment layer. Therefore, there is a problem that the layer thickness of the compound semiconductor layer is limited.

  The present invention has been made to solve the above-described problems, and can remove the convex portion of the compound semiconductor layer while suppressing the exposure of the active layer and the etching amount of the upper semiconductor layer without causing any adverse effects. An object is to provide a method for manufacturing a semiconductor device.

  A method of manufacturing a semiconductor device according to the invention of the present application includes an active layer, an upper semiconductor layer formed on the active layer, and a mask formed on the upper semiconductor layer on a part of a substrate. A laser part forming step for forming a laser part; a semiconductor layer forming process for forming a compound semiconductor layer having a convex portion at a part in contact with the side surface of the laser part and in contact with the laser part with a material containing In; And a wet etching step of removing the convex portion and flattening the compound semiconductor layer with an etchant containing hydrofluoric acid and acetic acid. Then, a (111) A plane is formed in the upper semiconductor layer under the mask by the wet etching process.

  According to the present invention, since the (111) A plane is formed in the upper semiconductor layer in the wet etching process and the side etching of the upper semiconductor layer is stopped, the exposure of the active layer and the etching amount of the upper semiconductor layer are suppressed, The convex part of the compound semiconductor layer can be removed.

2 is a cross-sectional view showing a laser unit according to Embodiment 1. FIG. It is sectional drawing which shows a compound semiconductor layer. It is sectional drawing of the compound semiconductor layer etc. in the middle of wet etching. It is sectional drawing of the semiconductor device at the time of completion | finish of wet etching. It is sectional drawing which shows having formed the contact layer. It is sectional drawing which shows having formed the resist. It is sectional drawing which shows the patterned resist. It is sectional drawing of the semiconductor device after wet etching. It is a graph which shows the relationship between the kind of mask, and the amount of side etching of an upper semiconductor layer. 7 is a cross-sectional view showing a laser unit according to Embodiment 2. FIG. It is sectional drawing which shows a compound semiconductor layer. It is sectional drawing which shows the compound semiconductor layer etc. of the initial stage of a wet etching process. It is sectional drawing of the semiconductor device after completion | finish of a wet etching process. 7 is a cross-sectional view showing a laser unit according to Embodiment 3. FIG. It is sectional drawing which shows a compound semiconductor layer. It is sectional drawing which shows the compound semiconductor layer etc. of the initial stage of a wet etching process. It is sectional drawing of the semiconductor device after completion | finish of a wet etching process. FIG. 6 is a plan view of a semiconductor device according to a fourth embodiment. It is sectional drawing which shows a laser part. It is sectional drawing which shows a compound semiconductor layer. It is sectional drawing of the semiconductor device which shows the initial stage of a wet etching process. It is sectional drawing of the semiconductor device after completion | finish of a wet etching process. It is a top view which shows the modification of the shape of a ridge stripe. It is a figure which shows the modification of a laser part.

  A method of manufacturing a semiconductor device according to an embodiment of the present invention will be described with reference to the drawings. The same or corresponding components are denoted by the same reference numerals, and repeated description may be omitted.

Embodiment 1 FIG.
In the method of manufacturing a semiconductor device according to the first embodiment of the present invention, a semiconductor device including compound semiconductor layers that function as current blocking layers on the left and right sides of a laser portion having a ridge stripe shape is formed. First, a laser part is formed. FIG. 1 is a cross-sectional view showing the laser unit 18. The substrate 10 is made of InP. An active layer 12 is formed on a part of the substrate 10. The active layer 12 has a multiple quantum well structure in which InGaAsP quantum well layers and InGaAsP barrier layers are alternately and repeatedly stacked. An upper semiconductor layer 14 made of InP is formed on the active layer 12.

  A mask 16 is formed on the upper semiconductor layer 14. The mask 16 is made of InGaAs. The active layer 12, the upper semiconductor layer 14, and the mask 16 constitute a laser unit 18. The process of forming the laser part 18 shown in FIG. 1 is referred to as a laser part forming process. In the laser part forming step, first, an active layer, an upper semiconductor layer, and a mask are formed on the entire surface of the substrate 10. Next, after patterning the mask, the upper semiconductor layer and the active layer that are not covered with the mask 16 are dry etched or wet etched. At this time, a part of the substrate is etched. Thus, the laser portion 18 shown in FIG. 1 is formed. Note that the laser unit 18 may be formed by another method.

  Next, a compound semiconductor layer is formed. FIG. 2 is a cross-sectional view showing the compound semiconductor layers 20A and 20B. The compound semiconductor layers 20 </ b> A and 20 </ b> B are formed on the (100) surface of the substrate 10 so as to be in contact with the side surface of the laser unit 18. The compound semiconductor layers 20A and 20B are made of InP. The active layer 12 and the upper semiconductor layer 14 are embedded with compound semiconductor layers 20A and 20B.

  In the compound semiconductor layers 20A and 20B, for example, p-InP layers and n-InP layers are alternately stacked to form a pnpn or npnp thyristor structure. However, the structure of the compound semiconductor layers 20A and 20B is not particularly limited as long as it functions as a current blocking layer.

  The compound semiconductor layers 20 </ b> A and 20 </ b> B have convex portions 20 a and 20 b at portions in contact with the laser portion 18, respectively. The convex portions 20a and 20b are portions that extend most upward in the compound semiconductor layers 20A and 20B. The (111) B surface is exposed at the protrusions 20a and 20b.

  The step of forming the compound semiconductor layers 20A and 20B shown in FIG. 2 is referred to as a semiconductor layer forming step. In the semiconductor layer forming step, the compound semiconductor layers 20A and 20B are epitaxially grown by metal organic chemical vapor deposition (MOCVD). There are two reasons why the convex portions 20a and 20b are formed. The first reason is the plane orientation dependence of the growth rate. When a group III-V crystal material is grown by MOCVD, the group V source gas supply amount is usually larger than the group III gas supply amount. Under such growth conditions, the growth rate of the (111) A plane is higher than that of the (100) plane, while the growth rate of the (111) B plane is lower. Therefore, convex parts 20a and 20b are formed.

  The second reason is that the material supplied on the mask migrates from the mask surface to the semiconductor substrate surface. As a result, the epitaxial growth of the compound semiconductor layer on the side of the mask is promoted, and the convex portions 20 a and 20 b are formed on the side of the mask 16. In addition, although the height of the convex parts 20a and 20b varies depending on the film forming conditions, it is, for example, about 0.1 μm to 3 μm.

  Next, the convex portion is removed by wet etching. FIG. 3 is a cross-sectional view of the compound semiconductor layer and the like during wet etching. For wet etching, an etchant having a mixing ratio of hydrobromic acid: acetic acid: water of 1: 3: 1 is used. The etching rate by this etchant depends on the crystal plane orientation of the object to be etched. When wet etching is started, etching of the (111) B surface of the protrusions 20a and 20b proceeds, and the protrusions 20a and 20b become smaller as shown in FIG.

  The wet etching ends when the convex portions 20a and 20b are removed and the compound semiconductor layers 20A and 20B become flat. FIG. 4 is a cross-sectional view of the semiconductor device at the end of wet etching. As a result of the etching of the (100) surface of the compound semiconductor layers 20A and 20B by wet etching, the upper semiconductor layer 14 under the mask 16 is side-etched. By this side etching, (111) A surfaces 14 a and 14 b are formed in the upper semiconductor layer 14 below the mask 16. The (111) A surfaces 14a and 14b are formed because the etching rate for the (111) A surfaces 14a and 14b is low and the etching stops at the (111) A surfaces 14a and 14b.

  As a result of forming the (111) A surfaces 14a and 14b in the upper semiconductor layer 14 by the wet etching process, the upper semiconductor layer 14 has a reverse mesa shape. Here, the ridge stripe direction is the (011) plane, but when the ridge stripe direction is the (0-11) plane, the upper semiconductor layer has a forward mesa shape.

  In this manner, the (100) plane is exposed on the surfaces of the compound semiconductor layers 20A and 20B, the surfaces of the compound semiconductor layers 20A and 20B are flattened, and the (111) A plane is formed on the side surfaces of the upper semiconductor layer 14. Is referred to as a wet etching step.

  Since the wet etching process is performed to remove the protrusions 20a and 20b, it is desirable to suppress etching of the (100) plane of the compound semiconductor layers 20A and 20B as much as possible. Etching of the (100) plane can be suppressed by using an etchant having a mixing ratio of hydrobromic acid: acetic acid: water of 1: 3: 1.

  In the experiment conducted by the inventors, the etching rate of the (100) plane in the wet etching process was 30 nm / min, and the etching rate of the (0-11) plane of the convex portion was 4500 nm / min. Therefore, wet etching of the (0-11) plane and the (01-1) plane can be advanced more rapidly than the (100) plane. This effect is because the plane orientation dependence of the etching rate of hydrobromic acid was promoted by acetic acid.

  However, the etching rate of the (0-11) plane depends on the concentration of the etchant. When the etchant is diluted with water, the dependency of the etching rate on the plane orientation tends to be weakened. In addition, when the mask is not formed on the convex portion, the etching rate of the (0-11) plane is increased. However, when the mask is formed on the convex portion, the (111) B surface of the convex portion is exposed. However, the (0-11) plane etching hardly proceeds.

  When the substrate 10 is damaged or the roughness of the substrate 10 is increased by dry etching for forming the laser portion 18 in FIG. 1, a surface other than the (100) plane is formed on the substrate surface. As a result, the etching rate of the (100) plane in the wet etching process increases to, for example, 56 nm / min. Therefore, when performing dry etching, damage and roughness of the (100) plane of the substrate should be reduced.

  Next, the mask is removed and a contact layer is formed. FIG. 5 is a cross-sectional view showing that the contact layer 22 has been formed. The contact layer 22 is formed of InGaAs by epitaxial growth so as to cover the compound semiconductor layers 20A and 20B and the upper semiconductor layer.

  Next, a resist is formed. FIG. 6 is a cross-sectional view showing that the resist 24 is formed. The resist 24 is formed on the entire surface. Next, this resist 24 is patterned. FIG. 7 is a cross-sectional view showing the patterned resist 24. Next, part of the contact layer 22 and part of the compound semiconductor layers 20A and 20B are wet-etched using the resist 24 as a mask. FIG. 8 is a cross-sectional view of the semiconductor device after wet etching. After the structure of FIG. 8 is formed, the resist 24 is peeled off, an insulating film is formed, electrodes are formed, and the surface process of the semiconductor device is completed. Further, the substrate is thinned until the thickness of the substrate reaches about 100 μm, a back electrode is formed, and the semiconductor device is completed by separating into chips. The completed semiconductor device is formed into a product through an assembly process such as packaging by forming a coat film on the chip end face.

  When the contact layer is epitaxially grown while leaving the convex portion of the compound semiconductor layer, crystal defects and crystal transition may occur in the contact layer. When a part of the contact layer is wet-etched, a part where a defect or the like exists is selectively etched, and the contact layer becomes abnormal in shape. The non-uniform shape near the optical waveguide changes the effective refractive index and scatters or reflects the guided light.

  Further, if the convex portion is left, the accuracy of formation of the resist 24 and its patterning is deteriorated, or the covering abnormality of the electrode formed on the contact layer is caused. As described above, if the process is continued while leaving the convex portions of the compound semiconductor layer, the subsequent steps may not be performed as intended.

  Therefore, in the method for manufacturing a semiconductor device according to the first embodiment of the present invention, the protrusions 20a and 20b are removed by a wet etching process, and the compound semiconductor layers 20A and 20B are planarized. The adverse effects described above can be avoided by flattening the compound semiconductor layers 20A and 20B.

  For example, when an etchant containing hydrochloric acid, acetic acid, hydrogen peroxide solution, and water is used in the wet etching process, the convex portion can be removed, but a (111) A surface having a low etching rate is formed in the upper semiconductor layer. It is hard to be done. Accordingly, the side etching of the upper semiconductor layer proceeds and the mask is peeled off, so that the etching of the upper semiconductor layer further proceeds and the active layer is exposed.

  In order to prevent this, an etchant having a mixture ratio of hydrobromic acid: acetic acid: water of 1: 3: 1 was used in the wet etching process of the first embodiment of the present invention. There are three main effects of using this etchant. First, when this etchant is used, a (111) A surface that is difficult to etch is formed in the upper semiconductor layer 14, and the side etching of the upper semiconductor layer 14 can be stopped. Therefore, since the mask can be left, exposure of the active layer can be avoided. Note that the (111) A plane referred to here includes a plane that is very close to the (111) A plane and is less likely to be etched like the (111) A plane.

  Second, an etchant having a mixture ratio of hydrobromic acid: acetic acid: water of 1: 3: 1 has a high etch rate with respect to the (111) B surface of the protrusion, so that the protrusion is quickly Can be removed. The side etching of the upper semiconductor layer 14 can be stopped while the etching of the protrusions 20a and 20b in the lateral direction is promptly performed, because the protrusions 20a and 20b are not covered with a mask, so that (111) The A plane cannot be held, but the upper semiconductor layer 14 is covered with the mask 16, so that the (111) A plane formed during the etching can be held.

  Third, an etchant having a mixture ratio of hydrobromic acid: acetic acid: water of 1: 3: 1 has a relatively low etch rate on the (100) plane, and therefore, etching of the (100) plane can be suppressed. it can. By the first to third effects, mask peeling can be avoided, the convex portions can be removed quickly, and etching of the (100) plane can be suppressed.

  As described above, according to the method for manufacturing a semiconductor device according to the first embodiment of the present invention, the convex portion of the compound semiconductor layer can be removed while suppressing the exposure of the active layer and the etching amount of the upper semiconductor layer. Since the contact layer 22 is not used as a mask in the wet etching process, the contact layer 22 can have a desired thickness. Moreover, since the contact layer 22 is formed after the formation of the compound semiconductor layers 20A and 20B, the dopant of the contact layer 22 is not diffused by the heat accompanying the formation of the compound semiconductor layers 20A and 20B. In addition, since the side etching of the upper semiconductor layer 14 is stopped on the (111) A surface of the upper semiconductor layer 14, it is not necessary to increase the thickness of the compound semiconductor layer in order to avoid the side etching, and the layers of the compound semiconductor layers 20A and 20B The thickness can be set freely.

By the way, if the adhesion between the mask 16 and the upper semiconductor layer 14 is low, the etchant used in the wet etching process enters the interface between the mask 16 and the upper semiconductor layer 14 and side etching of the upper semiconductor layer 14 proceeds. In the method of manufacturing a semiconductor device according to a first embodiment of the present invention, since using InGaAs material of the mask 16, as compared with the case of forming the mask with SiO _2, the adhesion of the mask 16 and the upper semiconductor layer 14 Is expensive. In order to improve the adhesion between the mask and the upper semiconductor layer, it is desirable to form the mask with an epitaxial layer.

FIG. 9 is a graph (measurement result) showing the relationship between the type of mask and the side etching amount of the upper semiconductor layer. The side etching amount is the etching amount of the upper semiconductor layer at the interface between the mask and the upper semiconductor layer. The mask is a SiO ₂ layer (layer thickness 100 nm, RF power 2 kW) formed by sputtering, a SiO ₂ layer (layer thickness 400 nm, RF power 1 kW) formed by sputtering, and an InGaAs layer (layer thickness 500 nm) formed by MOCVD. Three types were prepared. For wet etching, an etchant having a mixture ratio of hydrobromic acid: acetic acid: water of 1: 3: 1 was used.

As shown in FIG. 9, a small amount of side etching occurred in the mask formed of the SiO ₂ layer, but no side etching was observed in the mask formed of the InGaAs layer. When the mask is formed of InGaAs, the amount of side etching can be reduced because the adhesion between the InGaAs layer and the upper semiconductor layer (InP) is higher than the adhesion between the SiO ₂ layer and the upper semiconductor layer (InP). Conceivable.

Further, the material of the mask 16 is not particularly limited as long as it is a material in which the etch rate of the mask is slower than the etch rate of the convex portion in the wet etching process. For example, an insulating film such as a silicon oxide film (SiO ₂ ) or a silicon nitride film (SiN) or an epitaxial layer such as InP, AlInP, InGaP, AlGaInP, InGaAsP, InAs, InGaAs, AlInAs, AlGaInAs, or GaInNAs is used. Also good. Note that since the etching rate of the mask in the wet etching step can be reduced by increasing the Ga or As composition ratio of the mask, it is desirable to form the mask with a material having a high Ga or As composition ratio.

  The material of the compound semiconductor layers 20A and 20B is not particularly limited as long as it is a material containing In. The compound semiconductor layers 20A and 20B may be formed of any one of InP, AlInP, InGaP, AlGaInP, InGaAsP, InAs, InGaAs, AlInAs, AlGaInAs, and GaInNAs. Further, Ru, Zn, S, Fe, Be, Mg, or the like may be mixed into the compound semiconductor layers 20A and 20B as a dopant.

  The etchant used in the wet etching process is not particularly limited as long as it includes hydrobromic acid and acetic acid. For example, an etchant obtained by adding at least one of water, nitric acid, hydrogen peroxide solution, and bromine to hydrobromic acid and acetic acid may be used.

  The shape of the laser unit 18 is not limited to the vertical mesa type, and may be a forward mesa type or a reverse mesa type, or a shape different from these. These modifications can also be applied as appropriate to the method of manufacturing a semiconductor device according to the following embodiments.

  Since the semiconductor device manufacturing method according to the following embodiment has much in common with the semiconductor device manufacturing method according to the first embodiment, the description will focus on the differences from the first embodiment.

Embodiment 2. FIG.
In the first embodiment, the current blocking layer is formed as the compound semiconductor layer, but in the second embodiment, the optical modulator is formed as the compound semiconductor layer. That is, the semiconductor device manufacturing method according to the second embodiment forms a laser diode with an optical modulator. First, the laser part 18 shown in FIG. 10 is formed by the laser part forming step.

  Next, the compound semiconductor layer 60 shown in FIG. 11 is formed by the semiconductor layer forming step. The compound semiconductor layer 60 constitutes an optical modulator in contact with the (011) plane or the (0-1-1) plane of the laser unit 18. The compound semiconductor layer 60 includes a clad layer 62 formed on the substrate 10, an active layer 64 formed on the clad layer 62, and a clad layer 66 formed on the active layer 64. Since these layers are formed by the MOCVD method, a convex portion 66 a is formed in a portion of the cladding layer 66 that is in contact with the laser portion 18.

  Next, the process proceeds to the wet etching process. In the wet etching process, the protrusion 66a is formed using an etchant obtained by adding an oxidizing agent such as nitric acid, hydrogen peroxide solution, or bromine to an etchant having a mixture ratio of hydrobromic acid: acetic acid: water of 1: 3: 1. Remove. FIG. 12 is a cross-sectional view showing a compound semiconductor layer and the like in the initial stage of the wet etching process. FIG. 12 shows that the protrusion 66a is etched.

  The wet etching process ends when the protrusion 66a is completely removed and the cladding layer 66 is planarized. FIG. 13 is a cross-sectional view of the semiconductor device after the wet etching process. As a result of the etching of the cladding layer 66 on the (100) plane, a (111) A plane 14c is formed on the side surface of the upper semiconductor layer 14 below the mask 16, and the (111) A plane 14c forms the upper semiconductor layer 14's side. Etching stops.

  By the way, in the semiconductor layer forming step according to the second embodiment of the present invention, since the crystal grows in the (011) plane or the (0-1-1) direction, the (111) A plane may be formed on the convex portion 66a. is there. The (111) A plane is difficult to etch with an etchant containing hydrobromic acid and acetic acid.

  Therefore, in Embodiment 2 of the present invention, an oxidizing agent such as nitric acid, hydrogen peroxide, or bromine is added to an etchant of hydrobromic acid, acetic acid, and water to increase the (111) A-plane etching rate. It was. Therefore, the convex portion 66a can be reliably removed. By adding an oxidizing agent to the etchant, etching of the (111) A surface of the upper semiconductor layer 14 can be suppressed while promoting the etching of the (111) A surface of the convex portion 66a. This is because the convex portion 66a is not covered with the mask, so that etching is likely to proceed from a surface other than the (111) A plane, whereas the upper semiconductor layer 14 is covered with the mask 16 (111) A. This is because etching of surfaces other than the surface is difficult to proceed.

Embodiment 3 FIG.
In the method for manufacturing a semiconductor device according to the third embodiment, a laser diode, an optical modulator, and an optical waveguide are formed on a substrate. First, a laser part 18 shown in FIG. 14 is formed by a laser part forming step. Next, the optical modulator 100 is formed on the substrate 10. The optical modulator 100 has a mask 102 made of InGaAs as the uppermost layer.

  Next, the compound semiconductor layer 104 shown in FIG. 15 is formed by a semiconductor layer forming step. The compound semiconductor layer 104 is in contact with the (011) plane or (0-1-1) plane of the laser unit 18 and is in contact with the (011) plane or (0-1-1) plane of the optical modulator 100. The compound semiconductor layer 104 includes a cladding layer 106 made of InP as a material, an active layer 108 made of InGaAsP / InGaAsP formed on the cladding layer 106, and a cladding made of InP formed on the active layer 108. Layer 110 is provided. The compound semiconductor layer 104 is formed by MOCVD. The compound semiconductor layer 104 includes convex portions 110a and 110b.

  Next, the process proceeds to the wet etching process. In the wet etching process, an etchant having a mixture ratio of hydrobromic acid: acetic acid: water of 1: 3: 1 is used. FIG. 16 is a cross-sectional view showing a compound semiconductor layer and the like in the initial stage of the wet etching process. The wet etching process ends when the protrusions 110a and 110b are completely removed and the cladding layer 110 is planarized.

  FIG. 17 is a cross-sectional view of the semiconductor device after the wet etching process. As a result of the etching of the cladding layer 110 on the (100) plane, the (111) A surface 14 d is formed on the side surface of the upper semiconductor layer 14, and the (111) A surface 66 b is formed on the side surface of the cladding layer 66. Side etching of the upper semiconductor layer 14 is stopped by the (111) A surface 14d, and side etching of the cladding layer 66 is stopped by the (111) A surface 66b. An oxidizing agent may be added to the etchant.

  Thus, the convex portions of the compound semiconductor layer can be removed while suppressing the exposure of the active layer and the etching amount of the upper semiconductor layer. The semiconductor device manufacturing method according to the second and third embodiments is to manufacture a composite device in which a laser part and other elements are mixedly mounted on one substrate. In such a composite device, since the process of epitaxial growth on the compound semiconductor layer having a convex portion is repeated a plurality of times, the method for manufacturing a semiconductor device of the present invention is particularly effective. And it is not limited to comprising an optical modulator or an optical waveguide with a compound semiconductor layer, You may comprise an optical coupler, an optical amplifier, an EA modulator, or a phase modulator with a compound semiconductor layer.

Embodiment 4 FIG.
In the method of manufacturing a semiconductor device according to the fourth embodiment, an optical multiplexer / demultiplexer using multi-mode interference (MMI) is formed. FIG. 18 is a plan view of the semiconductor device according to the fourth embodiment. This semiconductor device includes a ridge stripe 150 and a compound semiconductor layer 152 that embeds the ridge stripe 150. The ridge stripe 150 has different shapes on the left side, the center, and the right side. That is, the ridge stripe 150 is one on the left side, has the maximum width at the center, and branches into two on the right side. The ridge stripe may have another shape in order to optimize the light transmission efficiency.

  First, a laser part 18 shown in FIG. 19 is formed by a laser part forming step. 19A is a cross-sectional view of a portion corresponding to line II ′ of FIG. 18, FIG. 19B is a cross-sectional view of a portion corresponding to line II-II ′ of FIG. 18, and FIG. 19C is a cross-sectional view of FIG. It is sectional drawing corresponding to an III 'line. Note that ABC in FIGS. 20, 21, and 22 has the same meaning as ABC in FIG.

  Next, compound semiconductor layers 20A, 20B, and 20C shown in FIG. 20 are formed by a semiconductor layer forming step. The compound semiconductor layers 20A, 20B, and 20C are formed of InP and function as a current blocking layer. The compound semiconductor layer 20A has a convex portion 20a, the compound semiconductor layer 20B has a convex portion 20b, and the compound semiconductor layer 20C has two convex portions 20c.

  Next, the convex portion is removed by a wet etching process. In the wet etching process, an etchant having a mixture ratio of hydrobromic acid: acetic acid: water of 1: 3: 1 is used. FIG. 21 is a cross-sectional view showing an initial stage of the wet etching process. The wet etching process ends when the convex portions are completely removed and the compound semiconductor layers 20A, 20B, and 20C are planarized. FIG. 22 is a cross-sectional view after the wet etching process.

  FIG. 22A shows (111) A surfaces 14e and 14f formed on the side surface of the upper semiconductor layer 14. FIG. 22B shows (111) A surfaces 14 g and 14 h formed on the side surface of the upper semiconductor layer 14. FIG. 22C shows (111) A surfaces 14 i and 14 j formed on the side surface of the upper semiconductor layer 14. An oxidizing agent may be added to the etchant used in the wet etching process.

  An optical multiplexer / demultiplexer using multi-mode optical interference has a portion where the mask width becomes wide in order to connect a plurality of optical waveguides. In the semiconductor layer forming step, a large amount of gas species migrates on a wide mask, so that the convex portion on the side of the mask becomes large. Therefore, the method of the present invention that can remove the protrusion while preventing the mask from peeling is particularly effective. In the optical multiplexer / demultiplexer, the transmission efficiency can be improved by flattening the surface of the compound semiconductor layer.

  FIG. 23 is a plan view showing a modification of the shape of the ridge stripe. The ridge stripe 150 in FIG. 23A is a straight type. The ridge stripe 150 in FIG. 23B is a flare type. The ridge stripe 150 in FIG. 23C is a bent optical waveguide type. The ridge stripe 150 in FIG. 23D is a branch type. The ridge stripe 150 in FIG. 23E is a Mach-Zehnder waveguide type. The planar shape of the ridge stripe and the planar shape of the mask are the same. That is, a ridge stripe having an arbitrary shape can be formed by changing the planar shape of the mask.

  The features of the embodiments described so far may be combined as appropriate.

By the way, the laser part 18 in Embodiment 1-4 was set as the very simple structure which has the active layer 12, the upper semiconductor layer 14, and the mask 16. FIG. However, the configuration of the laser unit 18 is not limited to such a simple configuration, and various modifications can be made.
That is, the laser unit 18 can be variously modified as long as it has the mask 16, the upper semiconductor layer 14, and the active layer 12. For example, the upper semiconductor layer 14 may be formed of a plurality of semiconductor layers having a clad layer as the uppermost layer.

  FIG. 24 is a diagram illustrating a modification of the laser unit 18. The laser unit 18 shown in FIG. 24 constitutes a distributed feedback laser element (DFB-LD). The upper semiconductor layer 14 has a multilayer structure including an optical confinement layer 14A, a barrier layer 14B, a guide layer 14C having a diffraction grating structure, and a cladding layer 14D. In addition, a lower semiconductor layer 200 including an optical confinement layer and a cladding layer is formed between the active layer 12 and the substrate 10. The guide layer 14 </ b> C may be formed between the active layer 12 and the substrate 10. The clad layer 14D may also serve as a contact layer or a cap layer. In that case, the cladding layer 14D may be referred to as a contact layer or a cap layer. The substrate 10 may be formed of an n-type semiconductor.

  In the case of the laser portion 18 of FIG. 24, the (111) A plane is formed in the cladding layer 14D in the wet etching process, and the side etching of the upper semiconductor layer 14 (cladding layer 14D) can be stopped. In this case, the exposure of the guide layer 14C and the etching amount of the cladding layer 14D can be suppressed. Of course, exposure of the active layer 12 can also be avoided.

  10 substrate, 12 active layer, 14 upper semiconductor layer, 14a, 14b (111) A plane, 16 mask, 18 laser part, 20A, 20B compound semiconductor layer, 20a, 20b convex part, 22 contact layer, 24 resist, 60 compound Semiconductor layer, 62, 66 cladding layer, 64 active layer, 66a convex part, 100 optical modulator, 102 mask, 104 compound semiconductor layer, 110a, 110b convex part, 150 ridge stripe, 152 compound semiconductor layer

Claims (7)

A laser part forming step of forming a laser part on a part of the substrate, comprising an active layer, an upper semiconductor layer formed on the active layer, and a mask formed on the upper semiconductor layer;
A semiconductor layer forming step of forming a compound semiconductor layer having a convex portion in a portion in contact with the side surface of the laser portion and in contact with the laser portion, using a material containing In;
A wet etching step of removing the protrusions and flattening the compound semiconductor layer with an etchant containing hydrobromic acid and acetic acid,
A method of manufacturing a semiconductor device, wherein a (111) A plane is formed in the upper semiconductor layer under the mask by the wet etching process. The compound semiconductor layer is in contact with the (011) plane or the (0-1-1) plane of the laser portion,
2. The method of manufacturing a semiconductor device according to claim 1, wherein the etchant includes an oxidizing agent in addition to the hydrobromic acid and the acetic acid. The upper semiconductor layer is made of InP;
3. The semiconductor device according to claim 1, wherein the compound semiconductor layer is formed of any one of InP, AlInP, InGaP, AlGaInP, InGaAsP, InAs, InGaAs, AlInAs, AlGaInAs, and GaInNAs. Production method.   4. The semiconductor device according to claim 1, wherein the mask is formed of a material whose etch rate of the mask is slower than an etch rate of the convex portion in the wet etching step. 5. Production method.   The method of manufacturing a semiconductor device according to claim 4, wherein the mask is formed of an epitaxial layer.   The method for manufacturing a semiconductor device according to claim 1, wherein a (100) plane is exposed on a surface of the compound semiconductor layer after the wet etching step.   The compound semiconductor layer constitutes a current blocking layer, an optical modulator, an optical waveguide, an optical coupler, an optical amplifier, an EA modulator, or a phase modulator. The manufacturing method of the semiconductor device as described in 2 ..

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